Shoe upper, method for producing the same, and shoe

ABSTRACT

Provided are a shoe upper that is capable of increasing the joining strength of joined portions of different members, protecting end portions, and improving contact with a foot and the appearance of the shoe, a method for producing the same, and a shoe. In a shoe upper of the present invention, different members are joined together through embroidery covering an end portion of at least one of the members, and at least one member forms a three-dimensional shape. A method for producing a shoe upper includes a step of joining different members together through basting such that at least one of the members has a three-dimensional shape, a step of temporarily fixing peripheral portions of joined portions of the basted upper to a base material with running stitches such that all the members have a two-dimensional shape, a step of joining the joined portions together through embroidery to cover an end portion of at least one of the members, and a step of removing the base material from a portion other than the joined portions, and returning at least one member to a three-dimensional shape by undoing the running stitches.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a shoe upper, a method for producing the same, and a shoe, and specifically relates to a shoe upper that is capable of increasing the joining strength of joined portions of different members that constitute the shoe upper, protecting end portions, and improving contact with a foot and the appearance of the shoe, a method for producing the same, and a shoe.

2. Description of Related Art

A shoe upper is sewn while making different members into a three-dimensional shape to follow the shape of a foot. Although single (double) stitching, which is a traditional sewing method, realizes a simple structure and freely realizes any shapes, there is a risk that an end portion will be frayed. Also, although a stitch-and-turn construction has a simple structure and an end portion thereof looks neat, a back surface (a surface that comes into contact with a foot) needs a cover, and thus overlapping portions of materials increase, resulting in poor contact with a foot. Although zigzag stitching realizes a simple structure and joining is possible through butting, the joining strength is low, and there is a high risk that an end portion will be frayed.

End treatment is usually performed in order to increase the joining strength of joined portions, reduce unevenness between joined portions, improve contact with a foot, prevent damage to an end portion, prevent end portions from being frayed, and increase aesthetic appearance, for example. End treatment is performed by covering an end portion or joined portions with another member, a hot-melt sheet, or the like, for example. In such end treatment, a member that is not essentially required is added, and thus the weight may be increased, or the thickness of the corresponding portion may be needlessly increased. Also, a member that is not essentially required is added, and thus the characteristics of an end portion may be changed and the end portion may break and stick into a foot when the end portion is bent, resulting in poor contact with a foot. End treatment in which a thermoplastic polyurethane film (TPU film) is used instead of a hot-melt sheet is limited to two-dimensional processing, and the joining strength is weak.

On the other hand, JP 2012-533404A discloses that a yarn is fixed by a covering layer while tensile characteristics of a base layer are changed by arranging strands on a shoe upper through embroidery. JP 2016-198481A discloses that an upper is constituted by embroidery threads having two different thicknesses. WO 2018/236346 discloses that the elasticity of an upper is controlled through embroidery.

JP 2012-533404A, JP 2016-198481A, and WO 2018/236346 are examples of related art.

SUMMARY OF THE INVENTION

In order to resolve the above-described issues, the present invention provides a shoe upper that is capable of increasing the joining strength of joined portions of different members, protecting end portions, and improving contact with a foot and the appearance of the shoe, a method for producing the same, and a shoe.

In one ore more embodiments, the present invention relates to a shoe upper, in which in the upper, different members are joined together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery covering an end portion of at least one of the members, and at least one of the members has a three-dimensional shape.

In one or more embodiments, the present invention relates to a method for producing a shoe upper, the method including a step of joining different members together through basting such that at least one of the members has a three-dimensional shape, a step of temporarily fixing peripheral portions of joined portions of the basted upper to a base material with running stitches such that all the members have a two-dimensional shape, a step of joining the joined portions together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery to cover an end portion of at least one of the members, and a step of removing the base material from a portion other than the joined portions, and returning at least one of the members to a three-dimensional shape by undoing the running stitches.

In one or more embodiments, the present invention relates to a shoe, the shoe comprising the shoe upper and a sole, in which the shoe upper is integrated with the sole.

According to the present invention, it is possible to provide a shoe upper that is capable of increasing the joining strength of joined portions of different members, protecting end portions, and improving contact with a foot and the appearance of the shoe, a method for producing the same, and a shoe.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic spread-out surface view of a shoe upper (of a left shoe) of one embodiment of the present invention.

FIG. 2 is a schematic spread-out back view of the shoe upper (of a left shoe) of one embodiment of the present invention.

FIG. 3 is a schematic surface view of different members that constitute a shoe upper (of a left shoe) of one embodiment of the present invention.

FIG. 4 is a schematic back view of different members that constitute the shoe upper (of a left shoe) of one embodiment of the present invention.

FIG. 5 is a schematic surface view of the shoe upper (of a left shoe) of one embodiment of the present invention in a state in which different members that constitute the upper are joined together through basting.

FIG. 6 is a schematic back view of the shoe upper (of a left shoe) of one embodiment of the present invention in a state in which different members that constitute the upper are joined together through basting.

FIG. 7 is a schematic surface view showing a state in which the basted upper (of a left shoe) is temporarily fixed to a base material with running stitches in one embodiment of the present invention.

FIG. 8 is a schematic surface view showing a state in which joined portions of the temporarily fixed upper (of a left shoe) are joined together through embroidery in one embodiment of the present invention.

FIG. 9 is a schematic back view showing a state in which joined portions of the temporarily fixed upper (of a left shoe) are joined together through embroidery in one embodiment of the present invention.

FIG. 10 is a schematic cross-sectional view of an embroidery apparatus used in one embodiment of the present invention.

FIG. 11 is a schematic perspective view of a shoe (a left shoe) of one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The inventor of this application conducted studies in order to resolve the above-described issues. As a result, the inventor found that it is possible to increase the joining strength of joined portions of different members that constitute a shoe upper, protecting an end portion, and improving contact with a foot and the appearance of the shoe by joining different members together through basting such that at least one of the members has a three-dimensional shape, temporarily fixing peripheral portions of joined portions of the basted upper to a base material with running stitches such that all the members have a two-dimensional shape, joining the joined portions together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery to cover an end portion of at least one of the members, and returning at least one of the members to a three-dimensional shape by removing the base material from a portion other than the joined portions and undoing the running stitches. Conventionally, embroidery is limited to two-dimensional processing, whereas in this application, as a result of using sewing capable of three-dimensional processing in combination with embroidery, it is possible to form at least one member into a three-dimensional shape while joining different members of a shoe upper together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery covering an end portion of at least one of the members, and thus it is possible to increase the joining strength of joined portions of the different members that constitute the shoe upper, protect an end portion, and improve contact with a foot and the appearance of the shoe. In one or more embodiments of the present invention, the feature that at least one of the members of the shoe upper has a three-dimensional shape means that when the shoe upper is placed flat on a horizontal table with its surface facing upward under no load conditions, at least one of the members has a portion rising above the table.

A shoe upper of a sports shoe includes, although not being particularly limited to, different members such as an instep cover for covering the instep side of a foot, a tongue portion, and shoelace passing portions (also referred to as “eyelets”), for example. Also, the shoe upper may include a plantar cover for covering the plantar side of a foot, or the like. The shoelace passing portions may be reinforced by artificial leather or the like.

The different members may be made of different materials or the same material. From the viewpoint of air permeability and weight reduction, the instep cover, the plantar cover, and the tongue portion may be formed using a mesh fabric, for example. There is no particular limitation on the mesh fabric, and it is possible to use warp knitted fabrics such as single raschel fabrics, double raschel fabrics, and tricot, and weft knitted fabrics such plain knitted fabrics and circular knitted fabrics as a mesh fabric. From the viewpoint of wearability and fittability to a foot, it is preferable that at least one of the different members is made of an elastic material. It is possible to use elastic yarns and non-elastic yarns in combination as appropriate in the elastic material.

In one or more embodiments of the present invention, although not particularly limited, examples of the elastic yarn include elastic yarns constituted by polyurethane-based elastic fibers (also referred to as spandex), polyetherester-based elastic fibers, and nylon fibers. An elastic yarn may be constituted by only elastic fibers, or may be a yarn obtained by combining elastic fibers with non-elastic fibers, which will be described later.

In one ore more embodiments of the present invention, there is no particular limitation on the non-elastic yarn, and examples thereof include non-elastic yarns constituted by non-elastic fibers such as polyester-based fibers such as polyethylene terephthalate and polytrimethylene terephthalate fibers; polyamide-based fibers; polyolefin-based fibers such polypropylene fibers; cellulosic fibers such as cuprammonium rayon, rayon, cotton, and bamboo fibers; and animal hair-based fibers such as wool.

In one ore more embodiments of the present invention, it is preferable that the upper includes an instep cover for covering an instep side of a foot, in which the instep cover has a structure in which a tongue portion and an instep cover main body are formed as a single body (which is so-called bootee structure), the tongue portion and the instep cover main body are joined together through embroidery covering an end portion of at least the instep cover main body, and the tongue portion has a three-dimensional shape. In one or more embodiments of the present invention, the structure in which “a tongue portion and an instep cover main body are formed as a single body” means that the tongue portion is not separable from the instep cover main body. In general, when the tongue portion and the instep cover main body are composed of different materials, both end portions of the tongue portion in the width direction of the foot can be joined to the instep cover main body by, e.g., sewing or bonding. The present invention allows the tongue portion and the instep cover main body to be joined together through embroidery covering the end portion of at least the instep cover main body. Thus, the joining strength of joined portions is increased, an end portion is protected, contact with a foot and the appearance of the shoe are improved, the fittability of a shoe to the instep side of a foot is further improved, and a comfortable feeling can be realized when the shoe is worn for a long period of time. The tongue portion may extend to a tiptoe. The upper may further include a plantar cover for covering the entire plantar side of the foot. In this case, the upper has a bag shape having a wearing opening. This further increases the unity of the upper and the sole.

In one or more embodiments of the present invention, the shoe upper can be produced in the following steps.

-   (1) A step of joining different members together through basting     such that at least one of the members has a three-dimensional shape     (basting step). -   (2) A step of temporarily fixing peripheral portions of joined     portions of the basted upper to a base material with running     stitches such that all the members have a two-dimensional shape     (temporarily fixing step). -   (3) A step of joining the joined portions together through one or     more embroideries selected from the group consisting of satin     embroidery and tatami embroidery to cover an end portion of at least     one of the members (embroidery step). -   (4) A step of removing the base material from a portion other than     the joined portions, and returning at least one of the members to a     three-dimensional shape by undoing the running stitches     (three-dimensional shape forming step).

Although there is no particular limitation, the basting may be performed using a sewing thread, and running stitching and embroidery may be applied using an embroidery thread. From the viewpoint of improving the joining strength of joined portions, the embroidery is preferably applied using an embroidery thread having a breaking elongation of 20% or more. The breaking elongation of an embroidery thread can be measured based on JIS L 1095 when the embroidery thread is a spun yarn, and the breaking elongation of an embroidery thread can be measured based on JIS L 1013 when the embroidery thread is a filament thread, for example.

In a shoe of one or more embodiments of the present invention, the shoe upper is integrated with a sole. There is also no particular limitation on a method for integrating the upper and the sole as a single body, and for example, the upper and the sole may be integrated with use of a usual cemented construction method or the like, for example. A general sole for a sport shoe may be selected and used as appropriate as a sole.

In one or more embodiments of the present invention, it is preferable to reinforce the tiptoe portion, the heel portion, and the eyelet portions of the shoe with use of artificial leather. The shape and holding properties of the shoe can be maintained through reinforcement. Out of these portions, the heel portion is not necessarily reinforced if the weight of the shoe truly needs to be reduced. Also, the surface of the shoe upper may be decorated as needed. In one or more embodiments of the present invention, the shoe may be provided with a shoelace.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. The same reference numerals indicate the same portions in the drawings. Note that the present invention is not limited to the embodiments shown in the following drawings.

FIG. 1 is a schematic spread-out surface view of an upper (of a left shoe) of one embodiment of the present invention. FIG. 2 is a schematic spread-out back view of the same upper. In this embodiment, an upper 1 includes an instep cover 2 and a plantar cover 3.

In the instep cover 2, a tongue portion 4 and an instep cover main body 5 are joined together and formed as a single body through embroidery 6 covering an end portion of the instep cover main body 5 (satin embroidery and/or tatami embroidery), and the tongue portion 4 has a three-dimensional shape. This increases the joining strength of joined portions, protects an end portion, and improves contact with a foot and the appearance of the shoe. The tongue portion 4 extends to the tiptoe. The width of the tongue portion 4 is gradually reduced from the ankle side toward the tiptoe. The tongue portion 4 may have the same width from the ankle side to the tiptoe.

The upper 1 has a reinforcing portion 7 of a shoelace passing portion (not shown). The inner instep cover main body 5 and the inner plantar cover 3 are constituted by one fabric 8 (one-piece), and the outer instep cover main body 5 and the outer plantar cover 3 are constituted by one fabric 9 (one-piece).

FIGS. 3 to 9 are schematic diagrams showing steps of producing the upper 1. FIG. 3 is a schematic surface view of different members that constitute a shoe upper (of a left shoe) of one embodiment of the present invention. FIG. 4 is a schematic back view of the different members. FIG. 5 is a schematic surface view of the shoe upper (of a left shoe) of one embodiment of the present invention in a state in which different members that constitute the upper are joined together through basting. FIG. 6 is a schematic back view of the shoe upper (of a left shoe) of one embodiment of the present invention in a state in which different members that constitute the upper are joined together through basting. FIG. 7 is a schematic surface view showing a state in which the basted upper (of a left shoe) is temporarily fixed to a base material with running stitches in one embodiment of the present invention. FIG. 8 is a schematic surface view showing a state in which joined portions of the temporarily fixed upper (of a left shoe) are joined together through embroidery in one embodiment of the present invention. FIG. 9 is a schematic back view showing a state in which joined portions of the temporarily fixed upper (of a left shoe) are joined together through embroidery in one embodiment of the present invention.

First, as shown in FIGS. 3 and 4, a material for constituting the tongue portion 4, a material 8 (an inner material 8) for constituting the inner instep cover main body and the inner plantar cover, a material 9 (an outer material 9) for constituting the outer instep cover main body 5 and the outer plantar cover 3, and a material for constituting the reinforcing portions 7 of shoelace passing portions (not shown) are prepared.

Then, as shown in FIGS. 5 and 6, the material for constituting the tongue portion 4, the inner material 8, and the outer material 9 are subjected to basting 10 such that the tongue portion 4 has a three-dimensional shape. At this time, the material for constituting the reinforcing portions 7 is also basted 10 to the material for constituting the tongue portion 4, the inner material 8, and the outer material 9.

Then, as shown in FIG. 7, peripheral portions of the joined portions of a basted upper 20 are temporarily fixed to a base material 30 with running stitches 40 such that all the members have a two-dimensional shape. The running stitches 40 may be formed in a peripheral portion of a joined portion located about 1 to 10 mm away from the joined portion in the width direction of a foot, for example. A reinforcing material such as a reinforcing non-woven fabric used in embroidery may be used as the base material 30, for example.

Then, as shown in FIGS. 8 and 9, a joined portion of the material for constituting the tongue portion 4 and the inner material 8, and a joined portion of the material for constituting the tongue portion 4 and the outer material 9 are subjected to embroidery 6 (satin embroidery or tatami embroidery) to cover the end portions of the inner material 8 and the outer material 9. At this time, also, the material for constituting the reinforcing portions 7, the material for constituting the tongue portion 4, the inner material 8, and the outer material 9 are integrated through embroidery. Then, the upper 1 shown in FIGS. 1 and 2 can be obtained as a result of the tongue portion 4 returning to a three-dimensional shape due to the base material 30 being removed from a portion other than the joined portions (embroidery) 6 and the running stitches 40 being undone.

FIG. 10 is a schematic cross-sectional view of an embroidery apparatus used in one embodiment of the present invention. This embroidery apparatus 50 includes a base 51, a needle 52 provided with a needle thread, and a bobbin thread 53 wound around a bobbin. The base material 30 is disposed on the base 51, the basted upper 20 is disposed thereon, and embroidery 6 is applied using the needle 52 provided with the needle thread, and the bobbin thread 53 wound around the bobbin. Note that, before embroidery 6 is applied, the basted upper 20 is temporarily fixed to the base material 30 with running stitches 40 such that all the members have a two-dimensional shape. Although, for the description, the base 51, the base material 30, the basted upper 20, and the embroidery (joined portions) 6 are separated from each other in FIG. 10, they are actually in contact with each other.

FIG. 11 is a schematic perspective view of a shoe (a left shoe) of one embodiment of the present invention. In a shoe 100, the upper 1 and a sole 60 are integrated.

In the upper 1, the instep cover 2 further includes shoelace passing portions 12 and 13 through which a shoelace 11 passes. The shoelace passing portion 12 may be provided by partially integrating a lace or the like having a predetermined thickness with the instep cover main body 5 to constitute a shoelace passing portion having a predetermined size. The shoelace passing portion 12 may be provided by applying embroidery around holes to form holes having a predetermined size in the tongue portion 4.

The shoe 100 includes a tiptoe reinforcing portion 14 and a heel counter 15. The tiptoe reinforcing portion 14 may be constituted by artificial leather, for example. The heel counter 15 may be constituted by resin. The heel counter 15 is provided with a lining material. Also, a wearing opening 200 is formed.

The above-described embodiments are to be considered in all respects merely as examples of the present invention and not limiting. Persons skilled in the art relating to the present invention may construct various embodiments employing the principles of the present invention, without departing from the spirit and essential characteristics of the present invention when considering the above-described teaching, even if not explicitly stated in this specification.

An upper of one or more embodiments of the present invention can be suitably used as an upper of a shoe, specifically, an upper of a sports shoe. Also, a shoe of one or more embodiments of the present invention can be suitably used as a shoe, specifically, a sports shoe.

The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limiting. The scope of the invention is indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. 

What is claimed is:
 1. A shoe upper, wherein, in the upper, different members are joined together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery covering an end portion of at least one of the members, and at least one of the members has a three-dimensional shape.
 2. The shoe upper according to claim 1, wherein the upper comprises an instep cover for covering an instep side of a foot, the instep cover has a structure in which a tongue portion and an instep cover main body are formed as a single body, and wherein the tongue portion and the instep cover main body are joined together through embroidery covering an end portion of at least the instep cover main body, and the tongue portion has a three-dimensional shape.
 3. The shoe upper according to claim 1, wherein the different members are made of different materials or the same material.
 4. The shoe upper according to claim 1, wherein at least one of the different members is made of an elastic material.
 5. The shoe upper according to claim 2, wherein the different members are made of different materials or the same material.
 6. The shoe upper according to claim 2, wherein at least one of the different members is made of an elastic material.
 7. The shoe upper according to claim 3, wherein at least one of the different members is made of an elastic material.
 8. A method for producing a shoe upper, comprising: a step of joining different members together through basting such that at least one of the members has a three-dimensional shape; a step of temporarily fixing peripheral portions of joined portions of the basted upper to a base material with running stitches such that all the members have a two-dimensional shape; a step of joining the joined portions together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery to cover an end portion of at least one of the members; and a step of removing the base material from a portion other than the joined portions, and returning at least one of the members to a three-dimensional shape by undoing the running stitches.
 9. The method for producing a shoe upper according to claim 8, wherein the different members comprise a tongue portion and an instep cover main body, and the tongue portion and the instep cover main body are joined together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery covering an end portion of at least the instep cover main body, and the tongue portion has a three-dimensional shape.
 10. The method for producing a shoe upper according to claim 8, wherein the embroidery is applied using a thread having a breaking elongation of 20% or more.
 11. The method for producing a shoe upper according to claim 9, wherein the embroidery is applied using a thread having a breaking elongation of 20% or more.
 12. A shoe, the shoe comprising: a shoe upper and a sole, wherein, in the upper, different members are joined together through one or more embroideries selected from the group consisting of satin embroidery and tatami embroidery covering an end portion of at least one of the members, and at least one of the members has a three-dimensional shape, and wherein the shoe upper is integrated with the shoe.
 13. The shoe according to claim 12, wherein the upper comprises an instep cover for covering an instep side of a foot, the instep cover has a structure in which a tongue portion and an instep cover main body are formed as a single body, and wherein the tongue portion and the instep cover main body are joined together through embroidery covering an end portion of at least the instep cover main body, and the tongue portion has a three-dimensional shape.
 14. The shoe according to claim 12, wherein the different members are made of different materials or the same material.
 15. The shoe according to claim 12, wherein at least one of the different members is made of an elastic material.
 16. The shoe according to claim 13, wherein the different members are made of different materials or the same material.
 17. The shoe according to claim 13, wherein at least one of the different members is made of an elastic material.
 18. The shoe according to claim 14, wherein at least one of the different members is made of an elastic material. 